# & Automatic Touchpad. # & Semi-Auto Touchpad. # Manual Touchpad

Transcription

1 # & Automatic Touchpad # & Semi-Auto Touchpad # Manual Touchpad Parts and Service Manual for Hydraulic Leveling Systems with Touch Pad Part Numbers , , , , and with Spring Return Jacks. 82-L0506 Released June, 2006 REV: 0C, November, 2012

2 Thank you for buying our Power Gear product! Before servicing this leveling system read this manual carefully and pay attention to the "notes" and "warnings". Remember that all leveling systems can be dangerous if used improperly. Also keep in mind safety, and use the leveling system in accordance with the operating instruction manual and common sense. This manual has been prepared for the service of the spring return jacks leveling system. Its purpose, aside from recommending standard service procedures and routine service requirements, is to promote safety through the use of accepted service practices. Read, understand and follow the safety instructions and notes of this manual and all safety messages on the components. It is recommended that all users of this equipment become familiar with the controls, components, and operation of this product before servicing the leveling system. Study this manual before servicing or operating, and keep it handy for future reference. TABLE OF CONTENTS Page 2: Page 3: Page 4: Page 5: Page 6: Page 7-9: Page 10-11: Page 12: Page 13: Page14-19: Page 20-21: Page 22-28: Table of Contents Warning/Before You Service the Coach System Description Recommended Fluids/Preventive Maintenance General Operation Instructions Metal Tank Hydraulic Pump Assemblies Plastic Tank Hydraulic Pump Assemblies Hose Identification Guide Hydraulic Fittings Touch Pad and Control Box Connections Wiring Diagrams Troubleshooting Guide 2

3 BEFORE YOU SERVICE THE COACH WARNING DO NOT USE THE POWER GEAR HYDRAULIC LEVELING SYSTEM (OR AIR SUSPENSION) TO SUPPORT VEHICLE WHILE UNDER COACH OR CHANGING TIRES. THE HYDRAULIC LEVELING SYSTEM IS DESIGNED AS A LEVELING SYSTEM ONLY. TIRE REPAIRS SHOULD BE PERFORMED BY A TRAINED PROFESSIONAL. ATTEMPTS TO CHANGE TIRES WHILE SUPPORTING THE VEHICLE WITH THE HYDRAULIC SYSTEM COULD RESULT IN DAMAGE TO THE MOTOR HOME AND/OR CAUSE SERIOUS INJURY OR EVEN DEATH. KEEP PEOPLE CLEAR OF COACH WHILE LEVELING SYSTEM IS IN USE. NEVER LIFT THE WHEELS OFF THE GROUND TO LEVEL THE COACH. DOING SO MAY CREATE AN UNSTABLE CONDITION. NEVER EXPOSE HANDS OR OTHER PARTS OF THE BODY NEAR HYDRAULIC LEAKS. HIGH PRESSURE OIL LEAKS MAY CUT AND PENETRATE THE SKIN CAUSING SERIOUS INJURY. DO NOT USE A HIGH PRESSURED WASH/RINSE SYSTEM ON ANY OF THE COMPONENTS ASSOCIATED WITH THE LEVELING SYSTEM. THIS INCLUDES THE PUMP, PUMP MOTOR, WIRING HARNESS, CONTROL, AND TOUCHPAD. THE USE OF A HIGH PRESSURE WASH/RINSE SYSTEM WILL VOID THE WARRANTY. CAUTION - PARK THE COACH ON A REASONABLY SOLID SURFACE OR THE JACKS MAY SINK INTO GROUND. ON SOFT SURFACES, USE LOAD DISTRIBUTION PADS UNDER EACH JACK. CAUTION - CHECK THAT POTENTIAL JACK CONTACT LOCATIONS ARE CLEAR OF OBSTRUCTIONS OR DEPRESSIONS BEFORE OPERATION. 3

4 BEFORE YOU OPERATE THE SYSTEM: 1. Make sure jack cylinder paths from the coach to the ground are clear and free of obstructions. 2. Make sure that the coach does not have objects leaning against the sides of it. As the coach will rise when the jack cylinders engage the ground and start to lift, moving the coach. 3. Place blocks under the jack cylinder foot pads for soft or low ground issues. Use as many blocks as needed to bring the depression, equal to or above the surrounding ground level. 4

5 MAJOR COMPONENT DESCRIPTION SYSTEM DESCRIPTION - The Power Gear electro-hydraulic leveling system consists of the following major components: (A) Touch Pad that is located inside the cab area of the coach. The touch pad communicates the input functions to the control box and receives status signals from the control. The available touch pads are: Manual touch pad (Part # ). Does not use a separate control box. Semi-Automatic touch pad (Part #'s or ). These use a separate control box. Automatic touch pad (Part #'s or ). These use a separate control box. (B) Control Box which has an internal leveling sensor and levels the coach to a calibrated point; it is mounted upside down inside a water proof location in the center of the coach. Contact the O.E.M for exact location. The control box communicates with the hydraulic pump assembly and the touch pad. A new or replacement control box does not have a stored level point; this must be set after installation. See reference documents for calibration procedure. The available control boxes are: Semi-Automatic control box (Part #'s or ). Automatic control box (Part #'s , , , and ). (C) Hydraulic Pump Assembly that consists of these components: motor, motor starter solenoid, pump, reservoir tank and manifold assembly. The manifold assembly has leg valve assemblies and a dump valve assembly. There is a manual override leg or dump valve with a trailer style connector or a packard style connector. There is also a non-override leg or dump valve with a trailer style connector or a packard style connector. (D) Hydraulic Hoses are used to connect the hydraulic pump assembly to the jack leg cylinders. The hoses are rated according to the output pressure of the pump assembly. (E) Jack Leg Cylinders with either internal or external springs that are rated at a lifting capacity appropriate for your coach. Each jack has a large 10" diameter (78.5 square inch) shoe for maximum mating area on different surfaces. External spring jacks have a spring that is mounted externally and connected both to the top at the jack bracket and to the shoe of the jack. Internal spring jacks have a spring welded to the inside top of the jack and connected to the top of the chrome rod. D) Hydraulic Hoses Item A Item B C) Hydraulic Pump Assembly E) Jack Leg Cylinders 5 Touch Pad and Control Box

6 RECOMMENDED HYDRAULIC FLUIDS The fluids listed here are acceptable to use in your pump assembly. Contact the coach manufacturer or selling dealer for information about what specific fluid was installed in your system. Please consult factory before using any other fluids. In most applications, Type A automatic transmission fluid (ATF, Dexron III, etc.,) will work satisfactorily. Mercon V is also recommended as an alternative fluid for Power Gear leveling systems operating in environments with large temperature swings Operating in cold temperatures (less than -10 F) may cause the jacks to extend and retract slowly. For cold weather operation, fluid specially-formulated for low temperatures may be desirable, Mobil DTE 11M, Texaco Rando HDZ-15HVI, Kendall Hyden Glacial Blu, or any Mil. Spec. H5606 hydraulic fluids are recommended for cold weather operation. PREVENTATIVE MAINTENANCE PROCEDURES To retain the quality for the leveling system use genuine Power Gear parts and service assistance. For the correct part or information for a particular leveling system always mention the part number listed on the major components label before contacting Power Gear or the OE.M. Also know the year, make, and model of the RV you are working on for further assistance. WARNING: Your coach should be supported at both front and rear axles with jack stands before working underneath, failure to do so may result in personal injury or death. 1. Check the fluid level every month. Fill the reservoir with the jacks in the fully retracted position. On vertical pump assemblies, the fluid should be within 1/4 inch of the fill port lip and checked only with all jacks retracted. On horizontal pump assemblies, the fluid level should be up to the weep hole on the side of the reservoir tank and checked only with all jacks retracted. 2. Change fluid every 24 months. 3. Inspect and clean all hydraulic pump electrical connections every 12 months. 4. Remove dirt and road debris from jacks as needed. 5. If jacks are down for extended periods, it is recommended to spray exposed chrome rods with a silicone lubricant every seven days for protection. If your coach is located in a salty environment (within 60 miles of coastal areas), it is recommended to spray the rods every 2 to 3 days. 6. Jacks equipped with grease fittings at the bottom of the cylinder should be greased with light weight lithium grease using a hand pump style grease gun only. 2 or 3 pumps should be sufficient for every uses. 7. Do not use a high pressured was/rinse system on any of the components associated with the leveling system. This includes the pump, pump motor, wiring harness, control and touchpad. THE USE OF A HIGH PRESSURE WASH/RINSE SYSTEM WILL VOID THE WARRANTY. 6

7 GENERAL OPERATING INSTRUCTIONS TO EXTEND THE JACKS: 1. Start the engine of the coach; this will insure proper voltage to the fuse which feeds the motor starter solenoid and control box. This fuse is provided by the O.E.M.; contact them for location and size. The batteries provide voltage to the hydraulic pump assembly and control box for correct operation. Some controls require a minimum of 13.1VDC to come out of "WAIT" mode. 2. Power the touch pad on by pressing the ON/OFF button. The LED will light up under the button indicating the touch pad is on. The touch pad will communicate with the control box to power the touch pad on; the control box will now be ready to accept the next input function. 3. Choose the function of manually leveling (MAN button) or automatically leveling (AUTO button) the coach by selecting the corresponding button. Press the AUTO button and it will dump the air (if using the 4 pin AUX connector on the control box, and it is programmed accordingly) and the system will level the coach to the calibrated point stored in the control box. Press and hold the MAN button for 5 seconds until the LED is lit under the button and it will dump the air (if using the 4 pin AUX connector on the control box, and it is programmed accordingly). Use the 4 directional buttons to extend the jacks. Pressing right button will operate the right rear jack; pressing left button will operate the left rear jack. Pressing the front button will operate both front jacks. Pressing the rear button will operate both rear jacks. The touch pad communicates with the control box to energize the leg valve(s) to extend the jack(s) and level the coach. 4. Turn off the touch pad. The touch pad stops communicating with the control box. 5. Turn off the ignition. The control box removes the power for the touch pad. TO RETRACT THE JACKS: 1. Start the engine of the coach, this will insure proper voltage to the fuse which feeds the motor starter solenoid and control box. This fuse is provided by the O.E.M.; contact them for location and size. 2. Power the touch pad on by pressing the ON/OFF button. The LED will light up under the button indicating the touch pad is on. The touch pad will communicate with the control box, and will now be ready to accept the next input function from the touch pad. 3. Press and release the RETRACT ALL JACKS button. The touch pad communicates with the control box to energize the leg valves and the dump valve on the hydraulic pump assembly. The jack springs pull on the foot pads and push the fluid back into the reservoir tank of the hydraulic pump assembly. 4. When the jacks are fully retracted the "jacks down" light on the touch pad will go off. When the float switch rises to the "open" position in the reservoir tank of the pump assembly, this is communicated to the control box, which then turns off the jacks down light on the touch pad within seconds. 7

8 VERTICAL METAL TANK PUMP ASSEMBLIES ITEM PART # DESCRIPTION QTY APPLICATION Complete power unit (1.5 gal. capacity) Complete power unit w/manual override knob on end of valves Complete power unit Complete power unit Valve manifold assembly (used w/ pump # ) present 8, Valve manifold assembly (used w/ pump # ) Valve manifold assembly (used w/ pump # ) present Valve manifold assembly w/manual override valves (used w/ ) Motor + Bearing S Tank replacement service kit (2.0 gal only) present Fill plug Breather cap/dip stick (used with pump # only) Push-in breather cap and dipstick present Grommet, push-in breather cap Drain plug See T.I.P. sheet 82-L0512 for fluid sensor/float switch ID 1 7 See T.I.P. sheet 82-L0509 and 82-L0510 for testing the fluid sensor or float switch Pump harness Pump harness w/packard connector present Dump valve assembly w/o manual override Dump valve assembly w/manual override knob on end of valves present Motor starter solenoid present Air breather Pump/motor assembly (used with pump assembly # ) (obsolete) , 2, 4, 5, Pump/motor assembly (used with pump assembly # ) present Pump/motor assembly (used with pump assembly # ) (obsolete) Pump/motor assembly (used with pump assembly # ) (obsolete) Leg valve assembly w/trailer connector 9 Leg valve assembly w/packard connector and manual override knob on present end of valve 5

9 THE DIFFERENCE IS IN THE DETAILS P /N: S IZ E: MISHAWAKA, INDIANA S /N: HORIZONTAL METAL TANK PUMP ASSEMBLIES Weep Hole 9 HYDRAULIC POWER UNIT level 5 A 8 7 ITEM PART # DESCRIPTION A QTY APPLICATION Complete 3-valve pump assy gal. capacity w/manual override knob on end of valves (obsolete) present gal. capacity w/manual override knob on end of valves gal. capacity w/o manual override valves (obsolete) Complete 4-valve pump assy gal. capacity w/o manual override valves (obsolete) gal. capacity w/o manual override valves (obsolete) gal. capacity w/o manual override knob on end of valves gal capacity w/manual override knob on end of valves (obsolete) gal capacity w/manual override knob on end of valves gal capacity w/manual override knob on end of valves Manifold assembly w/manual override valves Manifold assy. pump # s & present Manifold assy. pump # s & present Manifold assy. pump # present Manifold assembly w/o manual override valves Manifold assy. pump # s and present Leg valve assembly w/trailer connector present 1 Leg valve assembly w/packard connector and manual override knob on end of valve present 3 See T.I.P. sheet 82-L0512 for fluid sensor/float switch ID 1 See T.I.P. sheet 82-L0511 for testing the fluid sensor or float switch Breather cap and dipstick present Push-in breather cap and dipstick (pump assy ) present Grommet, push-in breather cap present gal. reservoir (obsolete) gal. reservoir (obsolete) Pump harness present Motor + Bearing only present Pump/motor assy. for power unit assy s and Pump/motor assy. for power unit assy Pump/motor assy. for power unit assy s and (obsolete) Pump/motor assy. for power unit assy s and present Motor starter solenoid present Dump valve assembly w/o manual override present Dump valve assembly w/manual override knob on end of valves present 9

10 3 OR 4 JACK LEG VALVE ASSEMBLY PRESENT Valve manifold assembly ITEM PART # DESCRIPTION QTY APPLICATION 1,3, S Rear hose connector kit present 1,3, * Front hose connector kit present Leg valve assembly w/trailer connector (Shown) 1 5 Leg valve assembly w/packard connector and manual override knob present on end of valve (Not shown) O-ring kit present Valve manifold assembly, pump # present Valve manifold assembly, pump # Valve manifold assembly, pump # Valve manifold assembly, pump # & present Valve manifold assembly, pump # & Valve manifold assembly, pump # * F port has 2 springs 10

11 VERTICAL PLASTIC TANK PUMP ASSEMBLIES ITEM PART # DESCRIPTION QTY APPLICATION Complete 4-valve pump assembly gal. capacity w/manual override knob on end of valves present gal. capacity w/manual override knob on end of valves present gal. capacity w/manual override knob on end of valves present gal. capacity w/manual override knob on end of valves present Manifold assembly w/manual override valves 6, Valve manifold assembly (used w/ pump # ) present 6, Valve manifold assembly (used w/ pump # ) present 6, Valve manifold assembly (used w/ pump # and ) present Motor and bearing present 2 For plastic tank replacement kit information see T.I.P. sheet 82-L present Push in breather cap present Grommet, push in breather cap present See T.I.P. sheet 82-L0512 for fluid sensor/float switch ID 1 5 See T.I.P. sheet 82-L0509 and 82-L0510 for testing the fluid sensor or float switch 1 Not shown Pump harness w/trailer style connector (for pump assy. # ) present Not shown Pump harness w/packard style connector (for pump assy. # , and ) present Dump valve assembly present Dump valve assembly w/packard style connector present Motor starter solenoid present 1, Pump /motor / tank assy present Leg valve assembly w/trailer connector present Leg valve assembly w/packard connector and manual override knob on end of valve present 11

12 HORIZONTAL PLASTIC TANK PUMP ASSEMBLIES ITEM PART # DESCRIPTION QTY APPLICATION 1-8 Complete 4-valve pump assy gal. capacity w/manual override knob on end of valves present gal. capacity w/manual override knob on end of valves present gal. capacity w/manual override knob on end of valves present gal. capacity w/manual override knob on end of valves present Manifold assembly w/manual override valves Valve manifold assembly (used w/pump # ) present 6, Valve manifold assembly (used w/pump # and ) present Valve manifold assembly (used w/pump # ) present Motor and bearing present 2 For plastic tank replacement kit information see T.I.P. sheet 82-L present 3 See T.I.P. sheet 82-L0512 for fluid sensor/float switch ID See T.I.P. sheet 82-L0511 for testing the fluid sensor or float switch Push in breather cap present Grommet, push in breather cap present Not shown Pump harness (used on pump assemblies # , ) present Not shown Pump harness (used on pump assembly ) present Not shown Pump harness (used on pump assembly ) present Dump valve present Dump valve w/packard connector present Motor starter solenoid present 1, Pump /motor / tank assy. (2.0 gal) present 1, Pump /motor / tank assy. (1.5 gal) present Leg valve assembly ( and ) 3 8 Leg valve assembly w/packard connector and manual override knob on end of valve present 12

13 HOSE IDENTIFICATION GUIDE 1/4" Hose # 080-XX XXX - II Letter A B C D E F G Hose fitting at each end Definition #4 37 deg female swivel end, 7/16-20 thread per S.A.E. J514/J.I.C #6 37 deg female swivel end, 9/16-18 thread per S.A.E. J514/J.I.C 90 deg short bend tube, #4 37 deg female swivel 7/16-20 thread per S.A.E. J514/J.I.C 90 deg short bend tube, #6 37 deg female swivel 9/16-18 thread per S.A.E. J514/J.I.C 45 deg short bent tube, #4 37 deg female swivel 7/16-20 thread per S.A.E. J514/J.I.C #4 37 deg male rigid end 7/16-20 thread per S.A.E. J514/J.I.C #6 37 deg male rigid end 9/16-18 thread per S.A.E. J514/J.I.C Example: Hose assembly # 080-AA264-II: The 080 indicates a 1/4" hose diameter "AA" indicates it uses a # 4 37 deg female swivel end fittings on both ends. The overall length of the hose is 264" long. 3/8" Hose # 08- X XXX X XX CR = Curbside Rear CF = Curbside Front RR = Roadside Rear RF = Roadside Front Letter A B C D E F G Hose fitting at each end Definition #4 37 deg female swivel end, 7/16-20 thread per S.A.E. J514/J.I.C #6 37 deg female swivel end, 9/16-18 thread per S.A.E. J514/J.I.C 90 deg short bend tube, #4 37 deg female swivel 7/16-20 thread per S.A.E. J514/J.I.C 90 deg short bend tube, #6 37 deg female swivel 9/16-18 thread per S.A.E. J514/J.I.C 45 deg short bent tube, #4 37 deg female swivel 7/16-20 thread per S.A.E. J514/J.I.C #4 37 deg male rigid end 7/16-20 thread per S.A.E. J514/J.I.C #6 37 deg male rigid end 9/16-18 thread per S.A.E. J514/J.I.C 13 T = Top B = Bottom N = N/A Example: Hose assembly # 08-A360TRR: The 08 indicates 3/8" hose diameter "A" indicates it uses a #4 37 deg female swivel end fittings on both ends The overall length of the hose is 360" long TRR indicates it connects to the top port of the roadside rear jack.

14 HYDRAULIC FITTINGS Fittings: WO11380 Reducers:

15 MANUAL TOUCH PAD CONTROL 2004-Present touchpad control (front view) touchpad control (rear view) ITEM NOTE PART # DESCRIPTION QTY APPLICATION 1 Not shown Auxiliary harness connector present 5021-XXX Pump harness connector 2 Not shown present XXX Pump harness (with fuse) 5010-XXX 3 Not shown Main power connector present 5018-XXX -XXX = length of harness in inches Note: See TIP Sheet # 204 for calibration instructions. Item #1 Auxiliary Harness Connector Item #3 Main Power Connector Pin #1 Pin #2 Pin #3 Pin #4 Fill output to the airbag valve. Energized with +12vdc to fill airbags. Fill output to the airbag valve. Ground to fill airbags. Dump output to the airbag valve. Energized with +12vdc to dump airbags. Dump output to the airbag valve. Ground to dump airbags. Item #2 Pump Harness Connector Pin #1 Pin #2 Pin #3 Pin #4 Pin #5 Pin #6 Input from park brake. Has continuity to ground when the park brake is engaged. Input from neutral safety switch. Can measure as either +12vdc or ground. Not used. Not used. Input from ignition. Energized with +12vdc when the coach is running. Input from neutral safety switch. Can measure as either +12vdc or ground. Pin #1 Ground input. Pin #2 Float switch input. See TIP sheets 82-L0509, 82-L0510 and 82-L0511 to determine proper signals. Pin #3 Output to motor starter solenoid. Energized with +12vdc when the front/rear/left/right button(s) are pushed. Pin #4 Output to dump valve. Energized with +12vdc when the "retract all jacks" button is pushed. Pin #5 Output to roadside rear leg valve. Energized with +12vdc when left or rear button or retract button is pushed. Pin #6 Output to curbside rear leg valve. Energized with +12vdc when right or rear button or retract button is pushed. Pin #7 Output to front jack leg valve. Energized with +12vdc when front button or retract button is pushed. Pin #8 Input from motor starter solenoid. Energized with +12vdc to supply power to the touchpad control 15

16 SEMI-AUTOMATIC TOUCHPAD & CONTROLS touchpad Obsolete use S kit control box Obsolete use S kit ITEM NOTE PART # DESCRIPTION QTY APPLICATION 1 Not shown 5020-XXX 5018-XXX Main power connector present 2 Not shown 5019-XXX Touch pad harness connector Obsolete Not shown Auxiliary harness connector present 4 Not shown 5021-XXX Pump harness connector present Semi-auto control kit (touchpad, control box, touchpad harness) present -XXX = length of harness in inches Note: See TIP Sheet # 152 for calibration instructions. Item #1 Main Power Connector Item #3 Auxiliary Harness Connector Pin #1 Pin #2 Pin #3 Pin #4 Pin #5 Pin #6 Input from park brake. Has continuity to ground when the park brake is engaged. Input from neutral safety switch. Can measure as either +12vdc or ground. Not used. Not used. Input from ignition. Energized with +12vdc when the coach is running. Input from neutral safety switch. Can measure as either +12vdc or ground. Item #2 Touch Pad Harness Connector Pin #1 Output to the touchpad. Transmit signal 5-7vdc. Pin #2 Input from the touchpad. Receive signal 5-7vdc. Pin #3 Power (+12vdc) output to the touchpad. Pin #4 Ground output to the touchpad. Pin #1 Pin #2 Pin #3 Pin #4 Fill output to the airbag valve. Energized with +12vdc to fill airbags. Fill output to the airbag valve. Ground to fill airbags. Dump output to the airbag valve. Energized with +12vdc to dump airbags. Dump output to the airbag valve. Ground to dump airbags. Item #4 Pump Harness Connector Pin #1 Ground input. Pin #2 Float switch input. See TIP sheets 82-L0509, 82-L0510 and 82- L0511 to determine proper signals. Pin #3 Output to motor starter solenoid. Energized with +12vdc when the front/rear/left/right button(s) are pushed. Pin #4 Output to dump valve. Energized with +12vdc when the "retract all jacks" button is pushed. Pin #5 Output to roadside rear leg valve. Energized with +12vdc when left or rear button or retract button is pushed. Pin #6 Output to curbside rear leg valve. Energized with +12vdc when right or rear button or retract button is pushed. Pin #7 Output to front jack leg valve. Energized with +12vdc when front button or retract button is pushed. Pin #8 Input from motor starter solenoid. Energized with +12vdc to supply power to the touchpad control 16

17 SEMI-AUTOMATIC TOUCHPAD & CONTROL 2006-Present touchpad control box ITEM NOTE PART # DESCRIPTION QTY APPLICATION 1 Not shown 5020-XXX 5018-XXX Main power connector present 2 Not shown XXX Touch pad harness connector present 3 Not shown Auxiliary harness connector present 4 Not shown 5021-XXX Pump harness connector present Semi-auto control kit (touchpad, control box, touchpad harness) present -XXX = length of harness in inches Note: See TIP Sheet # 152 for calibration instructions. Item #1 Main Power Connector Item #3 Auxiliary Harness Connector Pin #1 Pin #2 Pin #3 Pin #4 Pin #5 Pin #6 Input from park brake. Has continuity to ground when the park brake is engaged. Input from neutral safety switch. Can measure as either +12vdc or ground. Not used. Not used. Input from ignition. Energized with +12vdc when the coach is running. Input from neutral safety switch. Can measure as either +12vdc or ground. Item #2 Touch Pad Harness Connector Pin #1 Output to the touchpad. Pin #1 Output to the touchpad. Transmit Transmit signal 5-7vdc. signal 5-7vdc. Pin #2 Input from the touchpad. Pin #2 Input from the touchpad. Receive Receive signal 5-7vdc. signal 5-7vdc. Pin #3 Power (+12vdc) output to Pin #3 Power (+12vdc) output to the the touchpad. touchpad. Pin #4 Ground output to the Pin #4 Ground output to the touchpad. touchpad. Pin #1 Fill output to the airbag valve. Energized with +12vdc to fill airbags. Pin #2 Fill output to the airbag valve. Ground to fill airbags. Pin #3 Dump output to the airbag valve. Energized with +12vdc to dump airbags. Pin #4 Dump output to the airbag valve. Ground to dump airbags. Item #4 Pump Harness Connector Pin #1 Ground input. Pin #2 Float switch input. See TIP sheets 82-L0509, 82-L0510 and 82- L0511 to determine proper signals. Pin #3 Output to motor starter solenoid. Energized with +12vdc when the front/rear/left/right button(s) are pushed. Pin #4 Output to dump valve. Energized with +12vdc when the "retract all jacks" button is pushed. Pin #5 Output to roadside rear leg valve. Energized with +12vdc when left or rear button or retract button is pushed. Pin #6 Output to curbside rear leg valve. Energized with +12vdc when right or rear button or retract button is pushed. Pin #7 Output to front jack leg valve. Energized with +12vdc when front button or retract button is pushed. Pin #8 Input from motor starter solenoid. Energized with +12vdc to supply power to the touchpad control 17

18 AUTOMATIC TOUCH PAD & CONTROL touchpad Obsolete use S control box Obsolete use S ITEM NOTE PART # DESCRIPTION QTY APPLICATION 1 Not shown 5020-XXX Main power connector present 2 Not shown 5019-XXX Touch pad harness connector Obsolete Not shown XXX Auxiliary harness connector present 4 Not shown 5021-XXX Pump harness connector present s Automatic control kit (touchpad, control box, touchpad harness) present -XXX = length of harness in inches Note: See TIP Sheet # 153 for calibration Item #1 Main Power Connector Item #3 Auxiliary Harness Connector Pin #1 Pin #2 Pin #3 Pin #4 Pin #5 Pin #6 Input from park brake. Has continuity to ground when the park brake is engaged. Input from neutral safety switch. Can measure as either +12vdc or ground. Not used. Not used. Input from ignition. Energized with +12vdc when the coach is running. Input from neutral safety switch. Can measure as either +12vdc or ground. Item #2 Touch Pad Harness Connector Pin #1 Output to the touchpad. Transmit signal 5-7vdc. Pin #2 Input from the touchpad. Receive signal 5-7vdc. Pin #3 Power (+12vdc) output to the touchpad. Pin #4 Ground output to the touchpad. Pin #1 Fill output to the airbag valve. Energized with +12vdc to fill airbags. Pin #2 Fill output to the airbag valve. Ground to fill airbags. Pin #3 Dump output to the airbag valve. Energized with +12vdc to dump airbags. Pin #4 Dump output to the airbag valve. Ground to dump airbags. Item #4 Pump Harness Connector Pin #1 Ground input. Pin #2 Float switch input. See TIP sheets 82-L0509, 82-L0510 and 82- L0511 to determine proper signals. Pin #3 Output to motor starter solenoid. Energized with +12vdc when the front/rear/left/right button(s) are pushed. Pin #4 Output to dump valve. Energized with +12vdc when the "retract all jacks" button is pushed. Pin #5 Output to roadside rear leg valve. Energized with +12vdc when left or rear button or the retract button is pushed. Pin #6 Output to curbside rear leg valve. Energized with +12vdc when right or rear button or retract button is pushed. Pin #7 Output to front jack leg valve. Energized with +12vdc when the front button or retract button is pushed. Pin #8 Input from motor starter solenoid. Energized with +12vdc to supply power to the touchpad control 18

19 AUTOMATIC TOUCH PAD & CONTROL 2005-Present touchpad and control box ITEM NOTE PART # DESCRIPTION QTY APPLICATION 1 Not shown 5020-XXX Main power connector present 2 Not shown XXX Touch pad harness connector present Not shown XXX Auxiliary harness connector present 4 Not shown 5021-XXX Pump harness connection present -XXX = length of harness in inches Note: See TIP Sheet # 153 for calibration Pin #1 Pin #2 Pin #3 Pin #4 Pin #5 Pin #6 Item #2 Touch Pad Harness Connector Pin #1 Pin #2 Pin #3 Pin #4 Item #1 Main Power Connector Input from park brake. Has continuity to ground when the park brake is engaged. Input from neutral safety switch. Can measure as either +12vdc or ground. Not used. Not used. Input from ignition. Energized with +12vdc when the coach is running. Input from neutral safety switch. Can measure as either +12vdc or ground. Output to the touchpad. Transmit signal 5-7vdc. Input from the touchpad. Receive signal 5-7vdc. Power (+12vdc) output to the touchpad. Ground output to the touchpad. Item #3 Auxiliary Harness Connector Pin #1 Fill output to the airbag valve. Energized with +12vdc to fill airbags. Pin #2 Fill output to the airbag valve. Ground to fill airbags. Pin #3 Dump output to the airbag valve. Energized with +12vdc to dump airbags. Pin #4 Dump output to the airbag valve. Ground to dump airbags. Item #4 Pump Harness Connector Pin #1 Ground input. Pin #2 Float switch input. See TIP sheets 82-L0509, 82-L0510 and 82- L0511 to determine proper signals. Pin #3 Output to motor starter solenoid. Energized with +12vdc when the front/rear/left/right button(s) are pushed. Pin #4 Output to dump valve. Energized with +12vdc when the "retract all jacks" button is pushed. Pin #5 Output to roadside rear leg valve. Energized with +12vdc when left or rear button or retract button is pushed. Pin #6 Output to curbside rear leg valve. Energized with +12vdc when right or rear button or retract button is pushed. Pin #7 Output to front jack leg valve. Energized with +12vdc when front button or retract button is pushed. Pin #8 Input from motor starter solenoid. Energized with +12vdc to supply power to the touchpad control 19

20 AUTOMATIC TOUCH PAD & CONTROL 2005-Present touchpad , and control box ITEM NOTE PART # DESCRIPTION QTY APPLICATION 1 N 5020-XXX Main power connector present 2 N XXX Touch pad harness connector present 3 N N/A Auxiliary harness 2 connector present 4 N/A Auxiliary harness connector present 5 N 5021-XXX Pump harness connector present -XXX = length of harness in inches Item #1 Main Power Connector Item #3 Auxiliary Harness 2 Connector Pin #1 Pin #2 Pin #3 Pin #4 Ignition Accessory +12vdc lights rocker switch No connection (open) No connection (open) No connection (open) Pin #1 Pin #2 Pin #3 Pin #4 Pin #5 Pin #6 Input from park brake. Has continuity to ground when the park brake is engaged. Input from neutral safety switch. Can measure as either +12vdc or ground. Not used. Not used. Input from ignition. Energized with +12vdc when the coach is running. Input from neutral safety switch. Can measure as either +12vdc or ground. Item #4 Auxiliary Harness Connector Pin #1 Remote status +12vdc output Pin #2 Remote status ground output Pin #3 Dash light +12vdc output Pin #4 Dash light ground output Pin #5 External auto Pin #6 External retract Pin #7 Air dump output +12vdc Pin #8 Air fill output +12vdc Item #5 Pump Harness Connector Item #2 Touch Pad Harness Connector Pin #1 Output to the touchpad. Transmit signal 5-7vdc. Pin #2 Input from the touchpad. Receive signal 5-7vdc. Pin #3 Power (+12vdc) output to the touchpad. Pin #4 Ground output to the touchpad. Pin #1 Ground input. Pin #2 Float switch input. See TIP sheets 82-L0509, 82-L0510 and 82- L0511 to determine proper signals. Pin #3 Output to motor starter solenoid. Energized with +12vdc when the front/rear/left/right button(s) are pushed. Pin #4 Output to dump valve. Energized with +12vdc when the "retract all jacks" button is pushed. Pin #5 Output to roadside rear leg valve. Energized with +12vdc when left or rear button or retract button is pushed. Pin #6 Output to curbside rear leg valve. Energized with +12vdc when right or rear button or retract button is pushed. Pin #7 Output to front jack leg valve. Energized with +12vdc when front button or retract button is pushed. Pin #8 Input from motor starter solenoid. Energized with +12vdc to supply power to the touchpad control 20

21 Wiring diagram for systems with control box part # s , , , , and Please Note: Horizontal pump assemblies , , and do not use a dump valve assembly.

22 Wiring diagram for systems with control box part # s , and

23 TROUBLESHOOTING TOUCH PAD WILL NOT TURN ON, ON/OFF LED DOES NOT LIGHT Coach ignition not in run position Touch pad has been left on for more than four minutes, auto shut off has occurred No voltage at the touchpad. Turn ignition to run position and have engine running. Push ON/OFF button until LED is lit on touch pad. Check harness at the touchpad on the 4 pin connector (see wiring diagram): Check between pin #3 (black power wire) and pin #4 (blue or green ground wire). There should be vdc between the pins. No voltage out of control box to the touchpad. No power to control box on ignition input signal Damaged or broken touchpad harness Ground wire disconnected or shorted at control box Check power out of control box at the 4 pin connector (see wiring diagram): Check between pin #3 (black power wire) and pin #4 (blue or green ground wire). There should be vdc between the pins. On the control box at the 6 pin connector (see wiring diagram): Check incoming voltage between pin #5 (ignition) and pin #1 (ground) of the 8 pin connector. There should be +12vdc between the pins. If low or no voltage is found, contact the OEM for further troubleshooting. Check connectors and wires for damage or broken wires. Fix accordingly. Pin 1 of the 8 pin connector is the main ground. Test from pin 1 to chassis ground, there should be continuity with ground. If none is found, repair or replace ground wire. Neutral safety switch wires shorted or broken at control box On the control box at the 6 pin connector (see wiring diagram): Check for voltage at pin #6. If it has +12vdc verify pin #2 at the 6 pin connector also has +12vdc. If pin #2 is ground, ground pin #6. If the control then operates, repair or replace wires or neutral safety switch. Parking brake wire not grounded, or faulty parking brake switch Faulty touch pad On the control box check for continuity between pin #1 of the 6 pin connector and ground. If there is no continuity, the switch is bad, the parking brake is not set, or the wires to the switch are bad. If all previous causes and actions do not apply replace touch pad. JACKS WILL NOT EXTEND AND THE PUMP IS NOT RUNNING Coach ignition not in run position Turn ignition to run position and have engine running. Touch pad has been left on for more than four minutes, auto shut off has Push ON/OFF button until LED is lit on touch pad. occurred Check for +12vdc at the large battery terminal of the motor solenoid, if no voltage or if voltage No power from battery to pump is less than +12vdc, recharge battery or replace power cable. Bad ground to pump assembly Motor starter solenoid blue wire defective (see wiring diagram) Motor starter solenoid defective Pump motor defective Inspect / clean surface of star washers around mounting bolt holes of pump assembly. The bolts lock into the pump block assembly through the pump mounting plate. Add a new ground from chassis to pump motor bolts. Check for +12vdc at the blue signal wire at the motor starter solenoid when the front or rear button is pushed. If no voltage, check blue wire at pin #3 of the 8 pin connector for +12vdc when the front or rear button is pushed. If no voltage is present, remove blue wire from starter solenoid and check again at pin #3 for +12vdc while front or rear button is pushed. If there is +12vdc, check the blue wire for continuity, if no continuity replace or repair blue wire. If no voltage is present at Pin 3, contact Power Gear Technical Support. Check for +12vdc at the blue signal wire at the motor starter solenoid when the front or rear button is pushed. If no voltage, check blue wire at pin #3 of the 8 pin connector for +12vdc when the front or rear button is pushed. If voltage is present, connect +12vdc to motor side terminal of starter solenoid; if motor runs, replace starter solenoid. Check for continuity between the motor and ground. Connect +12vdc to motor side terminal of motor starter solenoid; if motor does not run, replace pump motor (see TIP sheet 216 for details).

24 ONE OR MORE JACKS WILL NOT EXTEND AND THE PUMP IS RUNNING Coach ignition not in run position Turn ignition to run position and have engine running. Fluid level low; pump cavitating Fill tank to proper level with automatic transmission fluid (see TIP sheet 140). No power at control box to energize valve coils (see wiring diagram) Dump valve stuck open or defective valve Leg valve wires damaged Valve coil miss wired Leg valve coil defective Leg valve defective Pump harness defective Check for +12vdc at the control box between pin #8 (power) and pin #1 (ground) of the 8 pin connector. If there is no voltage present then see wiring diagram for power and ground inputs. Remove the dump valve assembly and bench test it by applying power and ground to the coil (not polarity sensitive). The valve should click as you apply power and ground, you can also see the pin moving in the end of the valve. If the valve clicks but you do not have pin movement, replace dump valve. NOTE- If there still is no pressure after replacing the valves, the pump may be faulty. See TIP sheet 215 for pump diagnostic details. Check for +12vdc at leg valve wires (see wiring diagram) at the pump assembly while pushing the front button or the rear button depending on which jack leg valve you are testing. If no +12vdc signal, check for continuity on each wire between coil and controller. Check for ground at the black wire or red wire for each leg valve at the pump assembly. Repair if necessary. Check wiring diagram for correct location of wiring to the leg valve assemblies. Check coil for continuity, if none replace valve coil. Swap jack leg valve with one of the working jack leg valves and extend jacks. If jack(s) extend then replace cartridge valve. Check for ground at the black or red wire for each leg valve at pump assembly harness. If there is none, repair the wire. While pushing the button to extend the jacks, check for +12vdc at the purple, orange and yellow wires at the leg valves. If no voltage is measured check for +12vdc at the 8 pin connector on pin #7 (purple), pin #6 (orange) and pin #5 (yellow) at the control box. If voltage is present, repair the wires. If no voltage is present check the touchpad for trouble codes (see TIP sheet 184). If no trouble codes check for proper signals on the 6 pin harness see "touch pad will not turn on, indicator light does not light ". If proper signals are present, replace the controller. Pump itself is damaged See TIP sheet 215 for details. Remove tank and disassemble pump for visual inspection. Lubricate the jack Obstructions in jack pad Broken jack spring(s) JACK(S) WILL NOT RETRACT OR WILL NOT RETRACT FULLY While the jacks are extended down spray the chrome rod with silicone spray. If the jacks have a zerk fitting in the bottom collar of the jack assembly apply all purpose lithium grease. Three pumps with a manual grease gun are recommended. Retract the jacks and then extend the jacks. Lubricate the jacks again as above. Repeat this process 2 more times. Remove any rocks or foreign material out of the foot pad before retracting the jacks. Replace jack spring (see TIP sheet 34 and TIP Sheet 82-L0505). Jack rod guide is rusted or dirty Clean the chrome rod and grease rod guide if equipped with grease fittings. Otherwise lubricate with silicone fluid as described above. It may be necessary to reseal jack or replace. System overfilled with fluid Drain fluid to the recommended level (see TIP sheet 140). Dump valve wires damaged While pushing retract all jacks button check for +12vdc on the green wire at the dump valve. If no +12vdc, check for continuity on green wire between coil and controller. Check for ground at the black wire at the dump valve. Repair if necessary.

25 Check the float switch for operation. Check the float switch for proper orientation, see label on tank of pump assembly for orientation (vertical tanks only). For fluid sensor and float switch ID chart use TIP sheet 82-L0512. Jacks down light not lit on touch pad For testing of horizontal fluid sensors or float switches use TIP sheet 82-L0511. For testing of vertical fluid sensor or float switches use TIP sheets 82-L0509 and 82-L0510. Check for continuity on brown wire from float switch to control. Check for ground to float on black wire. Dump valve coil defective Check coil for continuity, if none replace valve. Dump valve defective Replace valve. While pushing the front or rear buttons check for +12vdc on the 8 pin connector at pin #5 Jack leg valve wire defective (yellow), pin #6 (orange) and pin #7 (purple). See wiring diagram for jack leg valve designations. Check for continuity from control box to jack coil, if none replace wire Jack leg valve ground wire defective Check for ground at the coil terminal black or red wire, repair if necessary Jack leg valve coil defective Check coil for continuity, if none replace leg valve Jack valve faulty Swap with another jack valve that is working correctly and test. Replace cartridge valve Shunt valve clogged Remove corresponding hose fitting on manifold to gain access to shunt valve. Clean valve passages with solvent and compressed air. Shunt valve spring damaged Replace spring. Hose damaged Replace kinked or damaged hose (damage may not be visible externally) Lubricate the jack Jack rod guide is rusted or dirty Broken jack spring(s) Shunt valve clogged Shunt valve spring damaged Hose damaged Internal failure within jack ANY JACK RETRACTS VERY SLOWLY While the jacks are extended down spray the chrome rod with silicone spray. If the jacks have a zerk fitting in the bottom collar of the jack assembly apply all purpose lithium grease. Three pumps with a manual grease gun are recommended. Retract the jacks and then extend the jacks. Lubricate the jacks again as above. Repeat this process 2 more times. Clean the chrome rod and grease rod guide if equipped with grease fittings. Otherwise lubricate with silicone fluid as described above. It may be necessary to reseal jack or replace. Replace jack spring (see TIP sheet 34 and TIP sheet 82-L0505). Remove corresponding hose fitting on manifold to gain access to shunt valve. Clean valve passages with solvent and compressed air. Replace spring. Replace kinked or damaged hose (damage may not be visible externally). Rebuild / replace components of jack as necessary. ANY JACK RETRACTS WITH NO POWER, WITH POSSIBLE POPPING SOUND Check for vertical coil in hoses. Remove the vertical coil if present then fully extend all the Air in system jacks and retract fully. Repeat this for 4 cycles waiting a few minutes between cycles, check fluid level in between cycles and refill tank as necessary (see TIP sheet 140). While the jacks are extended down spray the chrome rod with silicone spray. If the jacks have a zerk fitting in the bottom collar of the jack assembly apply all purpose lithium grease. Three Lubricate the jack pumps with a manual grease gun are recommended. Retract the jacks and then extend the jacks. Lubricate the jacks again as above. Repeat this process 2 more times. Due to changes in temperature, expanding and contracting of fluid will magnify the problem of Jack legs create popping sound popping jacks; see the recommended hydraulic fluid for cold operating weather. Contaminated fluid Replace fluid (see TIP sheet 140 and 141). Leg valves stuck open Remove leg valve, clean or replace. Dump valve contaminated Remove dump valve, clean or replace. Dump valve stuck open Replace valve. All leg valves and dump valve stuck Replace all the valves. open

26 JACKS DOWN LIGHT ON TOUCH PAD WILL NOT LIGHT WITH JACKS EXTENDED Fluid sensor faulty Harness wire faulty Fluid sensor miss adjusted Open circuit on the brown sensor wire Defective light on touch pad Refer to TIP sheet 82-L0512 for identifying the float sensor and float switch. To test horizontal fluid sensors or float switches use TIP sheet 82-L0511. To test vertical fluid sensor or float switches use TIP sheet 82-L0509 and 82-L0510. Check for ground at fluid sensor wires. The brown wire to pin #2 at controller should read ground when jacks are down. The other fluid sensor wire should read ground at all times. See TIP sheet 30, 54 or 81 for fluid sensor orientation on vertical tanks only. Check for continuity on the brown wire between the float sensor and pin #2 of the 8 pin connector at controller. If none replace wire. Apply +12vdc to pin #2 of the 8 pin connector with the key on. Turn on touch pad, if no light then replace the touch pad. JACKS DOWN LIGHT ON TOUCH PAD WILL NOT EXTINGUISH WITH JACKS RETRACTED Low fluid level Fill tank with automatic transmission fluid see (TIP sheet 140). Fluid sensor miss adjusted Fluid sensor faulty Open circuit on the brown sensor wire See TIP sheet 30, 54 or 81 for fluid sensor orientation on vertical tanks only. Refer to TIP sheet 82-L0512 for identifying the float sensor and float switch. To test horizontal fluid sensors or float switches use TIP sheet 82-L0511. To test vertical fluid sensor or float switches use TIP sheet 82-L0509 and 82-L0510. Check for continuity on the brown wire between the float sensor and pin #2 of the 8 pin connector at controller. If none replace wire. JACKS DOWN LIGHT AND ALARM WILL GO ON WHILE DRIVING, JACKS RETRACTED Low fluid level Fill tank with automatic transmission fluid see (TIP sheet 140). Fluid sensor miss adjusted Float sensor faulty Short in harness See tip sheet 30, 54 or 81 for fluid sensor orientation on vertical tanks only. Refer to TIP sheet 82-L0512 for identifying the float sensor and float switch. To test horizontal fluid sensors or float switches use TIP sheet 82-L0511. To test vertical fluid sensor or float switches use TIP sheet 82-L0509 and 82-L0510. Check float switch wires for open circuit. SYSTEM LEVELS BUT RETRACTS WHEN KEY IS TURNED OFF Improper wiring to 6 pin harness. See TIP sheets 195, 196, 197, 199, 200, 204, 205. SYSTEM DROPS DOWN SLIGHTLY AS KEY IS SHUT OFF Improper wiring to 6 pin harness. See TIP sheets 195, 196, 197, 199, 200, 204, 205. LEVELING SYSTEM RETRACTS WHEN KEY IS PUT INTO ACC POSITION Improper wiring to 6 pin harness See TIP sheets 195, 196, 197, 199, 200, 204, 205. SYSTEM WILL NOT AUTO RETRACT WHEN THE CHASSIS IS PUT INTO DRIVE Improper wiring to 6 pin harness. See TIP sheets 195, 196, 197, 199, 200, 204, 205. Neutral safety switch wires shorted At the 6 pin connector (see wiring diagram): Check for voltage at pin #6. If it has +12vdc verify pin #2 at the 6 pin connector also has +12vdc. If pin #2 is ground, ground pin #6 at the 6 pin. If the control then operates, repair or replace wires or neutral safety switch.